Century, Grand Prix, Impala, Intrigue, Lumina, Monte Carlo, Regal 2001-2005

Engine

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Removal & Installation



3.1L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Throttle body air inlet duct
     
    Air cleaner
     
    Engine mount struts
     
    Drive belt
     
    Knock Sensor (KS) electrical connector
     
    Heated Oxygen Sensor (HO 2 S) electrical connector
     
    Camshaft Position (CMP) sensor electrical connector
     
    Crankshaft Position (CKP) sensor electrical connector
     
    Manifold Air Pressure (MAP) sensor electrical connector
     
    Exhaust Gas Recirculation (EGR) valve electrical connector
     
    Evaporative (EVAP) emissions canister purge solenoid valve
     
    Throttle Position Sensor (TPS) electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Starter motor electrical connector
     
    Alternator electrical connector
     
    Ignition coil electrical connector
     
    Wiring harness ground connections
     
    Two body wiring harness-to-engine harness connectors
     
    Oil filter
     
    Catalytic converter pipe from the rear exhaust manifold
     
    Engine mount lower nuts
     
    Torque converter cover
     
    A/C compressor
     
    Right side splash shield
     
    Torque converter bolts
     
    Transaxle brace
     
    Radiator outlet hose from the engine
     
    Accelerator and cruise control cables
     
    Heater inlet and outlet hoses
     
    Vacuum hoses from the upper intake manifold
     
    Fuel feed and return hoses
     
    Power steering pump and reposition
     
    Radiator inlet and outlet hoses
     

  10.  
  11. Attach an engine lifting device.
  12.  
  13. Remove the transmission-to-engine bolts.
  14.  
  15. Remove the engine from the vehicle.
  16.  

To install:

  1. Install or connect the following:

    Engine to the vehicle
     
    Transmission-to-engine bolts and torque them to 55 ft. lbs. (75 Nm)
     

  2.  
  3. Remove the engine lifting device.
    NOTE
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.



    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Power steering lines to the pump and torque the fasteners to 20 ft. lbs. (27 Nm)
     
    Radiator inlet hose
     
    Heater inlet and outlet hoses
     
    Fuel feed and return hoses
     
    Vacuum hoses to the upper intake manifold
     

  4.  
  5. Remove the trim panel under the left instrument panel and detach the throttle cable from the top of the pedal then squeeze the retainer and push the cable through the bulkhead to remove it.
  6.  
  7. Install or connect the following:

    New accelerator cable
     
    Cruise control cable
     
    Radiator outlet hose
     
    Transmission brace and torque the transmission bolts to 32 ft. lbs. (43 Nm) and the engine bolts to 46 ft. lbs. (63 Nm)
     
    Right side splash shield and torque the fasteners to 44 inch lbs. (5 Nm)
     
    Torque converter bolts and torque them to 47 ft. lbs. (63 Nm)
     
    A/C compressor and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Starter motor and torque the bolts to 32 ft. lbs. (43 Nm)
     
    Torque converter cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Engine mount lower nuts and torque them to 32 ft. lbs. (43 Nm)
     
    Catalytic converter pipe to the rear exhaust manifold and torque the fasteners to 26 ft. lbs. (35 Nm)
     
    Oil Filter
     
    Two body wiring to engine harness
     
    Wiring harness grounds
     
    Ignition coil electrical connector
     
    Alternator electrical connector
     
    A/C compressor electrical connector
     
    Starter motor electrical connector
     
    IAC valve electrical connector
     
    TPS electrical connector
     
    EVAP canister purge solenoid valve electrical connector
     
    EGR valve electrical connector
     
    MAP sensor electrical connector
     
    CKP sensor electrical connector
     
    CMP sensor electrical connector
     
    HO 2 sensor electrical connector
     
    KS electrical connector
     
    Drive belt
     
    Engine mount struts and torque the fasteners to 35 ft. lbs. (48 Nm)
     
    Hood and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Throttle body air inlet duct
     
    Air cleaner
     
    Negative battery cable
     

  8.  
  9. Fill the engine with clean oil.
  10.  
  11. Fill the coolant system.
  12.  
  13. Start the vehicle and check for leaks, repair if necessary.
  14.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Throttle body air inlet duct
     
    Air cleaner
     
    Engine mount struts
     
    Drive belt
     
    Knock Sensor (KS) electrical connector
     
    Heated Oxygen (HO 2 S) sensor electrical connector
     
    Camshaft Position (CMP) sensor electrical connector
     
    Crankshaft Position (CKP) sensor electrical connector
     
    Manifold Air Pressure (MAP) sensor electrical connector
     
    Exhaust Gas Recirculation (EGR) valve electrical connector
     
    Evaporative (EVAP) emissions canister purge solenoid valve
     
    Throttle Position (TPS) sensor electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Starter motor electrical connector
     
    Alternator electrical connector
     
    Ignition coil electrical connector
     
    Wiring harness ground connections
     
    Two body wiring harness-to-engine harness connectors
     
    Oil filter
     
    Catalytic converter pipe from the rear exhaust manifold
     
    Engine mount lower nuts
     
    Torque converter cover
     
    A/C compressor
     
    Right side splash shield
     
    Torque converter bolts
     
    Transaxle brace
     
    Radiator outlet hose from the engine
     
    Accelerator and cruise control cables
     
    Heater inlet and outlet hoses
     
    Vacuum hoses from the upper intake manifold
     
    Fuel feed and return hoses
     
    Power steering pump and reposition
     
    Radiator inlet and outlet hoses
     

  10.  
  11. Attach an engine lifting device.
  12.  
  13. Remove the transmission-to-engine bolts.
  14.  
  15. Remove the engine from the vehicle.
  16.  

To install:

  1. Install or connect the following:

    Engine to the vehicle
     
    Transmission-to-engine bolts and torque them to 55 ft. lbs. (75 Nm)
     

  2.  
  3. Remove the engine lifting device.
    NOTE
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.



    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Power steering lines to the pump and torque the fasteners to 20 ft. lbs. (27 Nm)
     
    Radiator inlet hose
     
    Heater inlet and outlet hoses
     
    Fuel feed and return hoses
     
    Vacuum hoses to the upper intake manifold
     

  4.  
  5. Remove the trim panel under the left instrument panel and detach the throttle cable from the top of the pedal then squeeze the retainer and push the cable through the bulkhead to remove it.
  6.  
  7. Install or connect the following:

    New accelerator cable
     
    Cruise control cable
     
    Radiator outlet hose
     
    Transmission brace and torque the transmission bolts to 32 ft. lbs. (43 Nm) and the engine bolts to 46 ft. lbs. (63 Nm)
     
    Right side splash shield and torque the fasteners to 44 inch lbs. (5 Nm)
     
    Torque converter bolts and torque them to 47 ft. lbs. (63 Nm)
     
    A/C compressor and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Starter motor and torque the bolts to 32 ft. lbs. (43 Nm)
     
    Torque converter cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Engine mount lower nuts and torque them to 32 ft. lbs. (43 Nm)
     
    Catalytic converter pipe to the rear exhaust manifold and torque the fasteners to 26 ft. lbs. (35 Nm)
     
    Oil Filter
     
    Two body wiring to engine harness
     
    Wiring harness grounds
     
    Ignition coil electrical connector
     
    Alternator electrical connector
     
    A/C compressor electrical connector
     
    Starter motor electrical connector
     
    IAC valve electrical connector
     
    TPS sensor electrical connector
     
    EVAP canister purge solenoid valve electrical connector
     
    EGR valve electrical connector
     
    MAP sensor electrical connector
     
    CKP sensor electrical connector
     
    CMP sensor electrical connector
     
    HO 2 sensor electrical connector
     
    KS sensor electrical connector
     
    Drive belt
     
    Engine mount struts and torque the fasteners to 35 ft. lbs. (48 Nm)
     
    Hood and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Throttle body air inlet duct
     
    Air cleaner
     
    Negative battery cable
     

  8.  
  9. Fill the engine with clean oil.
  10.  
  11. Fill the coolant system.
  12.  
  13. Start the vehicle and check for leaks, repair if necessary.
  14.  

3.4L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Hood
     
    Cross vehicle brace
     
    Engine mount struts
     
    Drive belt
     
    Brake booster vacuum hose
     
    Heated Oxygen (HO 2 S) sensor electrical connector
     
    Secondary Air Injection (AIR) check valve electrical connector
     
    Exhaust Gas Recirculation (EGR) valve electrical connector
     
    Evaporative Emissions (EVAP) canister purge solenoid valve electrical connector
     
    Throttle Position (TPS) sensor electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Alternator electrical connector
     
    Ignition coil electrical connector
     
    Wiring harness grounds
     
    Two engine wiring harness connectors
     
    Lower radiator air baffle
     
    Engine splash shields
     
    Oil filter
     
    Vehicle Speed (VSS) sensor electrical connector
     
    Oil level sensor electrical connector
     
    Oil pressure switch electrical connector
     
    Engine block heater (if equipped)
     
    Knock (KS) sensor electrical connector
     
    Crankshaft Position (CKP) sensor
     
    A/C compressor electrical connector
     
    Catalytic converter
     
    Engine mount lower nuts
     
    Torque converter cover
     
    Starter motor
     
    A/C compressor without disconnecting the lines
     
    Torque converter bolts
     
    Transaxle brace
     
    Radiator outlet hose
     
    Accelerator and cruise control cables
     
    Vacuum hoses from the upper intake manifold
     
    Fuel feed and return hoses
     
    Power steering pump without disconnecting the hoses
     
    Heater inlet and outlet hoses
     
    Radiator inlet hose
     

  10.  
  11. Attach an engine lifting device.
  12.  
  13. Remove the transmission bolts.
  14.  
  15. Remove the engine from the vehicle.
  16.  

To install:

  1. Install or connect the following:
    NOTE
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.



    Engine to the transaxle and torque the bolts to 55 ft. lbs. (75 Nm)
     
    Radiator inlet hose
     
    Heater inlet and outlet hoses
     
    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Fuel feed and return hoses
     
    Vacuum hoses to the upper intake manifold
     

  2.  
  3. Remove the trim panel under the left instrument panel and detach the throttle cable from the top of the pedal then squeeze the retainer and push the cable through the bulkhead to remove it.
  4.  
  5. Install or connect the following:

    New accelerator cable
     
    Cruise control cable
     
    Radiator outlet hose
     
    Transmission brace and torque the transmission bolts to 32 ft. lbs. (43 Nm) and the engine bolts to 46 ft. lbs. (63 Nm)
     
    Torque converter-to-flywheel bolts and torque them to 47 ft. lbs. (63 Nm)
     
    A/C compressor and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Starter motor and torque the bolts to 32 ft. lbs. (43 Nm)
     
    Torque converter cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Engine mount lower nuts and torque them to 32 ft. lbs. (43 Nm)
     
    Catalytic converter and torque the nuts to 24 ft. lbs. (32 Nm)
     
    New oil filter
     
    VSS electrical connector
     
    Oil level sensor electrical connector
     
    Oil pressure switch electrical connector
     
    Engine block heater electrical connector
     
    KS electrical connector
     
    HO 2 S electrical connector
     
    CKP sensor electrical connector
     
    A/C compressor electrical connector
     
    Wiring harness grounds
     
    Lower radiator air baffle and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Engine splash shield and torque the fasteners to 18 inch lbs. (2 Nm)
     
    AIR check valve solenoid electrical connector
     
    EGR valve electrical connector
     
    EVAP canister purge solenoid valve electrical connector
     
    TPS electrical connector
     
    IAC valve electrical connector
     
    Alternator electrical connector
     
    Ignition coil electrical connector
     
    Wiring harness grounds
     
    Engine wiring harness connectors
     
    Drive belt
     
    Engine mount strut and torque the bolt to 35 ft. lbs. (48 Nm)
     
    Throttle body air inlet duct
     
    Cross vehicle brace and torque the nuts to 29 ft. lbs. (40 Nm)
     
    Hood and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  6.  
  7. Fill the engine oil.
  8.  
  9. Fill the engine coolant.
  10.  
  11. Inspect the transmission fluid level and top off if necessary.
  12.  
  13. Turn the ignition to the ON position several times to pressurize the fuel system.
  14.  
  15. Start the engine and inspect for any leaks, repair if necessary.
  16.  
  17. Check and top off the fluid levels if required.
  18.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Hood
     
    Cross vehicle brace
     
    Engine mount struts
     
    Drive belt
     
    Brake booster vacuum hose
     
    Heated Oxygen Sensor (HO 2 S) electrical connector
     
    Secondary Air Injection (AIR) check valve electrical connector
     
    Exhaust Gas Recirculation (EGR) valve electrical connector
     
    Evaporative Emissions (EVAP) canister purge solenoid valve electrical connector
     
    Throttle Position Sensor (TPS) electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Alternator electrical connector
     
    Ignition coil electrical connector
     
    Wiring harness grounds
     
    Two engine wiring harness connectors
     
    Lower radiator air baffle
     
    Engine splash shields
     
    Oil filter
     
    Vehicle Speed Sensor (VSS) electrical connector
     
    Oil level sensor electrical connector
     
    Oil pressure switch electrical connector
     
    Engine block heater (if equipped)
     
    Knock Sensor (KS) electrical connector
     
    Crankshaft Position (CKP) sensor
     
    A/C compressor electrical connector
     
    Catalytic converter
     
    Engine mount lower nuts
     
    Torque converter cover
     
    Starter motor
     
    A/C compressor without disconnecting the lines
     
    Torque converter bolts
     
    Transaxle brace
     
    Radiator outlet hose
     
    Accelerator and cruise control cables
     
    Vacuum hoses from the upper intake manifold
     
    Fuel feed and return hoses
     
    Power steering pump without disconnecting the hoses
     
    Heater inlet and outlet hoses
     
    Radiator inlet hose
     

  10.  
  11. Attach an engine lifting device.
  12.  
  13. Remove the transmission bolts.
  14.  
  15. Remove the engine from the vehicle.
  16.  

To install:

  1. Install or connect the following:
    NOTE
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.



    Engine to the transaxle and torque the bolts to 55 ft. lbs. (75 Nm)
     
    Radiator inlet hose
     
    Heater inlet and outlet hoses
     
    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Fuel feed and return hoses
     
    Vacuum hoses to the upper intake manifold
     

  2.  
  3. Remove the trim panel under the left instrument panel and detach the throttle cable from the top of the pedal then squeeze the retainer and push the cable through the bulkhead to remove it.
  4.  
  5. Install or connect the following:

    New accelerator cable
     
    Cruise control cable
     
    Radiator outlet hose
     
    Transmission brace and torque the transmission bolts to 32 ft. lbs. (43 Nm) and the engine bolts to 46 ft. lbs. (63 Nm)
     
    Torque converter-to-flywheel bolts and torque them to 47 ft. lbs. (63 Nm)
     
    A/C compressor and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Starter motor and torque the bolts to 32 ft. lbs. (43 Nm)
     
    Torque converter cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Engine mount lower nuts and torque them to 32 ft. lbs. (43 Nm)
     
    Catalytic converter and torque the nuts to 24 ft. lbs. (32 Nm)
     
    New oil filter
     
    VSS electrical connector
     
    Oil level sensor electrical connector
     
    Oil pressure switch electrical connector
     
    Engine block heater electrical connector
     
    KS electrical connector
     
    HO 2 S electrical connector
     
    CKP sensor electrical connector
     
    A/C compressor electrical connector
     
    Wiring harness grounds
     
    Lower radiator air baffle and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Engine splash shield and torque the fasteners to 18 inch lbs. (2 Nm)
     
    AIR check valve solenoid electrical connector
     
    EGR valve electrical connector
     
    EVAP canister purge solenoid valve electrical connector
     
    TPS electrical connector
     
    IAC valve electrical connector
     
    Alternator electrical connector
     
    Ignition coil electrical connector
     
    Wiring harness grounds
     
    Engine wiring harness connectors
     
    Drive belt
     
    Engine mount strut and torque the bolt to 35 ft. lbs. (48 Nm)
     
    Throttle body air inlet duct
     
    Cross vehicle brace and torque the nuts to 29 ft. lbs. (40 Nm)
     
    Hood and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  6.  
  7. Fill the engine oil.
  8.  
  9. Fill the engine coolant.
  10.  
  11. Inspect the transmission fluid level and top off if necessary.
  12.  
  13. Turn the ignition to the ON position several times to pressurize the fuel system.
  14.  
  15. Start the engine and inspect for any leaks, repair if necessary.
  16.  
  17. Check and top off the fluid levels if required.
  18.  

3.5L & 3.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the engine cooling system.
  8.  
  9. Remove or disconnect the following:
    CAUTION
    Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.



    Front wheels
     
    Lower air deflector
     
    Fuel injector sight shield
     
    Left diagonal brace
     
    Air cleaner assembly
     
    Radiator inlet hose
     
    Alternator
     
    Fuel lines from the rail and position
     
    Fuel vapor line
     
    Throttle and cruise cables with the mounting bracket from the throttle body
     
    Automatic range selector cable from the Park/Neutral Position (PNP) switch
     
    Vacuum brake booster hose from the booster
     
    Transaxle oil cooler lines from the radiator
     
    Heater hoses from the engine
     
    Right side AIR control valve, if equipped
     
    Upper engine electrical connectors, including grounds
     
    Lower AIR hose from the elbow, if equipped and discard the clamp
     
    Lower electrical connectors, including grounds and the harness retainer
     
    Fog lamp electrical connectors, if equipped
     
    Torque converter cover
     
    Starter
     
    Bolts attaching the engine flywheel to the torque converter
     
    Engine splash shields from the inner fender
     
    A/C compressor and position aside without disconnecting the lines
     
    Catalytic converter pipe from the rear exhaust manifold
     
    Bolts attaching the lower transaxle to the engine
     
    Connectors from the Wheel Speed Sensors, and unclip the harnesses from the lower control arms
     
    Drive axles from the steering knuckles
     



    Pinch bolt from the intermediate steering shaft
     
    Intermediate shaft from the steering gear
     
    Upper and lower engine wiring harnesses position them aside
     

  10.  
  11. Place a frame table under the engine/transaxle/frame. With an assistant, lower the vehicle to the frame table in order to support the engine/transaxle/frame.

    Bolts attaching the frame to the body
     
    Frame table with the engine/transaxle/frame from under the vehicle
     
    Power steering pump from the engine and lay the pump aside
     
    Secondary air injection check valve/pipe, if equipped
     
    Dipstick tube
     
    Exhaust manifolds and crossover pipe
     

  12.  
  13. Install an engine lifting device to the engine.

    Bolts attaching the engine mount bracket to the engine
     
    Transaxle brace
     
    Bolts attaching the upper transmission to the engine
     
    Engine from the transaxle/frame
     

  14.  

To install:

  1. Installation is the reverse of removal, please note the following torques:
  2.  
  3. Install or connect the following:

    Bolts attaching the transmission to the engine to 55 ft. lbs. (75 Nm)
     
    Frame bolts to 133 ft. lbs. (180 Nm)
     

  4.  
  5. Center the steering angle sensor.
  6.  
  7. Fill the engine with new oil.
    NOTE
    A filter change is recommended.

  8.  
  9. Fill the cooling system.
  10.  
  11. Perform the Crankshaft Position (CKP) system variation learn procedure.
  12.  
  13. Start the engine and check for leaks, repair if necessary.
  14.  

3.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the engine cooling system.
  8.  
  9. Remove or disconnect the following:
    WARNING
    Secure the front of the vehicle to the lift. The vehicle may become unstable as the engine/transaxle assembly is removed from the vehicle.



    Drive belt
     
    Fuel injector sight shield
     
    Power steering pump and move it aside
     
    Air intake duct from the throttle body
     
    Engine mount strut from the bracket
     
    Fuel lines from the fuel supply rail
     
    Fuel vapor line
     
    Throttle and cruise control cables with the bracket from the throttle body
     
    Range selector cable from the Park/Neutral Position (PNP) switch
     
    Brake booster vacuum hose from the engine
     
    Air conditioning vacuum hose from the engine
     
    Wiring harness from the engine and transaxle
     
    Radiator inlet hose from the engine
     
    Transaxle fluid cooler lines from the radiator
     
    Thermostat housing
     
    Surge tank inlet hose
     
    Heater hoses from the engine
     
    Lower radiator air deflector
     
    Secondary Air Injection (AIR) pipe from the AIR inlet valve
     
    Battery cables from the retainers
     
    Radiator outlet hose from the engine
     
    Alternator
     
    A/C compressor, move it aside without disconnecting the lines
     
    Torque converter cover
     
    Starter motor
     
    Flexplate-to-torque converter bolts
     
    Catalytic converter from the rear exhaust manifold
     
    Lower transaxle-to-engine bolts
     
    Front wheels and splash shields
     
    Fog lamp electrical connectors
     
    Wheel Speed Sensor (WSS) harness from the lower control arms
     
    Tie rod ends from the steering knuckles
     
    Lower ball joints from the steering knuckles
     
    Halfshafts
     
    Intermediate shaft from the steering rack
     

  10.  
  11. Position a frame table under the vehicle.
  12.  
  13. Lower the vehicle so the frame is resting on the frame table.
  14.  
  15. Remove the frame-to-chassis bolts.
    WARNING
    Do not damage the air conditioning compressor or lines when removing the frame from the vehicle.

  16.  
  17. Lift the vehicle from the engine/transaxle assembly.
  18.  
  19. Remove or disconnect the following:

    Remove the engine mount bracket bolts
     
    Remove the transmission brace
     
    Remove the engine from the transaxle
     

  20.  

To install:

Click image to see an enlarged view

Fig. Engine mount bracket bolt tightening sequence-3.5L engine

  1. Install or connect the following:

    Transaxle to the engine and torque the bolts to 55 ft. lbs. (75 Nm)
     
    Transaxle brace and torque the bolts to 32 ft. lbs. (43 Nm)
     
    Engine mount bracket to the front of the engine and torque the bolts to 43 ft. lbs. (58 Nm)
     
    Engine/transaxle assembly under the vehicle
     

  2.  
  3. Coat the sub-frame bushings with rubber lubricant.
  4.  
  5. Lower the vehicle onto the assembly. Align the sub-frame on the vehicle using 2 bolts or drill bits, 3 / 4 inches thick by 8 inches long through the alignment holes on the right side of the frame.
  6.  
  7. Install new frame-to-body bolts and torque them to 133 ft. lbs. (180 Nm) starting with the rear bolts and then the front bolts
  8.  
  9. Raise the vehicle and remove the frame table.
  10.  
  11. Install or connect the following:
    NOTE
    Be sure the shaft is fully seated on the stub before installing the pinch bolt.


    NOTE
    In order to avoid possible injury or vehicle damage, always use a new accelerator cable when replacing the engine assembly.



    Intermediate shaft to the steering rack and torque the pinch bolt to 35 ft. lbs. (48 Nm)
     



    Halfshafts
     
    Lower ball joints and torque the nuts to 40 ft. lbs. (50 Nm)
     
    Tie rod ends and torque the nuts to 22 ft. lbs. (30 Nm) plus an additional 120 degree turn
     
    WSS wiring harness to the lower control arm
     
    Splash shields
     
    Front wheels
     
    Fog lamp electrical connectors
     
    Catalytic converter to the rear exhaust manifold and torque the nuts to 53 inch lbs. (6 Nm)
     
    Flexplate-to-torque converter by aligning the matchmarks and torque the bolts to 47 ft. lbs. (63 Nm)
     
    Starter motor and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Torque converter cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    A/C compressor and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Lower radiator hose to the engine
     
    Battery cables in the retainers
     
    AIR pipe
     
    Lower radiator air deflector and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Thermostat housing and torque the bolts to 80 inch lbs. (9 Nm)
     
    Heater hoses
     
    Surge tank hose
     
    Transaxle fluid cooler lines to the radiator
     
    Upper radiator hose to the engine
     
    Wiring harness connectors to the engine/transaxle
     
    A/C vacuum hose to the engine
     
    Brake booster hose to the engine
     
    Shifter cable to the transaxle PNP switch
     

  12.  
  13. Remove the trim panel under the left instrument panel and detach the throttle cable from the top of the pedal then squeeze the retainer and push the cable through the bulkhead to remove it.
  14.  
  15. Install or connect the following:

    New throttle cable
     
    Cruise control cable to the throttle body
     
    Fuel vapor line
     
    Fuel lines to the supply rail
     
    Engine mount strut and torque the bolt to 35 ft. lbs. (48 Nm)
     
    Air duct to the throttle body
     
    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Fuel injector shield and torque the bolts to 27 inch lbs. (3 Nm)
     
    Drive belt
     
    Negative battery cable
     

  16.  
  17. Refill the cooling system.
  18.  
  19. Install a new oil filter and refill the engine with new oil.
  20.  
  21. Start the engine and check for leaks, repair if necessary.
  22.  

3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Matchmark the hood hinges and remove the hood.
  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Fuel injector sight shield
     
    Torque converter cover
     
    Starter motor
     
    Engine flywheel-to-torque converter bolts
     
    Transaxle bracket
     
    Engine mount lower nuts
     
    Catalytic converter pipe from the right exhaust manifold
     
    Oil level harness retainer from the engine
     

  12.  
  13. Unplug and reposition the following electrical connections:

    Vehicle Speed Sensor (VSS)
     
    Oil pressure sensor
     
    Oil level sensor
     
    Knock sensors
     
    Heated Oxygen Sensor (HO 2 S)
     

  14.  
  15. Remove or disconnect the following:

    Oil filter adapter housing
     
    Engine ground nut and engine ground from the transaxle stud
     
    Bolt and the stud which attach the lower transaxle to the engine
     

  16.  
  17. Lower the vehicle while supporting the transaxle.

    Air cleaner assembly
     
    Fuel lines from the fuel rail
     
    Fuel vapor line
     
    Throttle and cruise control cables and bracket from the throttle body
     
    Water pump pulley bolts, loosen only
     
    Drive belt
     
    Water pump pulley bolts and the pulley
     
    Right and left engine mount struts
     
    Engine mount brackets from the radiator support
     
    Positive battery cable
     
    Engine cooling fans
     
    Vacuum booster hose from the engine
     
    A/C vacuum hose from the engine
     
    Power steering pump and lay aside with the lines attached
     

  18.  
  19. Unplug the upper engine electrical connectors from the following components:

    Fuel injectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) valve
     
    Evaporative Emissions (EVAP) purge solenoid
     
    Exhaust Gas Recirculation (EGR) valve
     
    Manifold Absolute Pressure (MAP) sensor
     
    Upper engine wiring harness from retaining clips and reposition the engine wiring harness for engine removal
     
    Radiator inlet and outlet hoses from the engine
     
    Heater hoses from the drive belt tensioner
     
    A/C compressor from the engine and set aside without disconnecting the lines
     

  20.  
  21. Install an engine lifting device.

    Bolts that attach the upper transaxle to the engine
     
    Engine from the vehicle
     

  22.  

To install:

  1. Installation is the reverse of removal, please note the following torques:

    Bolts attaching the upper transaxle to the engine to 55 ft. lbs. (75 Nm)
     
    A/C compressor-to-bracket nuts to 22 ft. lbs. (30 Nm)
     
    Power steering bolts to 25 ft. lbs. (34 Nm)
     
    Water pump pulley bolts to 116 inch lbs. (13 Nm)
     
    Bolt and the stud attaching the lower transaxle to the engine to 55 ft. lbs. (75 Nm)
     
    Engine ground nut to 26 ft. lbs. (35 Nm)
     
    Engine mount lower nuts to 58 ft. lbs. (78 Nm)
     

  2.  
  3. Fill the engine with new oil.
    NOTE
    A filter change is recommended.

  4.  
  5. Fill the cooling system.
  6.  
  7. Perform the Crankshaft Position (CKP) system variation learn procedure.
  8.  
  9. Start the engine and check for leaks, repair if necessary.
  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Hood
     
    Fuel injector sight shield
     
    Throttle body air inlet duct
     
    Air cleaner
     
    Radiator inlet/outlet hoses
     
    A/C compressor without disconnecting the lines
     
    Starter motor wiring harness
     
    Accelerator and cruise control cables
     
    Wiring harness from the top of the engine
     
    Fuel lines from the fuel rail
     
    Fuel vapor line
     
    Power brake booster vacuum hose
     
    A/C vacuum hose
     
    Heater hoses
     
    Engine mount struts from the brackets
     
    Power steering pump and move it aside
     
    Torque converter cover
     
    Starter motor
     
    Flywheel-to-torque converter bolts
     
    Engine mount lower nuts
     
    Transaxle brace
     
    Catalytic converter pipe from the rear exhaust manifold
     
    Lower transaxle to engine bolts
     

  10.  
  11. Lower the vehicle and install a suitable engine lifting device.
  12.  
  13. Remove the upper transaxle to engine bolts.
  14.  
  15. Remove the engine from the vehicle.
  16.  

To install:

  1. Install the engine to the vehicle.
  2.  
  3. Torque the transmission-to-engine bolts to 55 ft. lbs. (75 Nm).
  4.  
  5. Remove the engine lifting device.
  6.  
  7. Install or connect the following:
    NOTE
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.



    Catalytic converter to the rear exhaust manifold. Torque the nuts to 26 ft. lbs. (35 Nm).
     
    Transaxle brace and torque the transaxle bolts to 32 ft. lbs. (43 Nm) and the engine bolts to 46 ft. lbs. (63 Nm)
     
    Engine mount lower nuts and torque them to 35 ft. lbs. (47 Nm)
     
    Flywheel-to-torque converter bolts and torque them to 47 ft. lbs. (63 Nm)
     
    Starter motor and torque the bolts to 32 ft. lbs. (43 Nm)
     
    Torque converter cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Power steering pump and torque the bolt to 25 ft. lbs. (34 Nm)
     
    Engine mount struts and torque the bolts to 35 ft. lbs. (48 Nm)
     
    Heater hoses
     
    A/C vacuum hose
     
    Power brake booster vacuum hose
     
    Fuel vapor line
     
    Fuel lines
     
    Wiring harness to the top of the engine
     

  8.  
  9. Remove the trim panel under the left instrument panel and detach the throttle cable from the top of the pedal then squeeze the retainer and push the cable through the bulkhead to remove it.
  10.  
  11. Install or connect the following:

    New throttle cable
     
    Cruise control cable to the throttle body
     
    Starter motor wiring harness
     
    A/C compressor and torque the bolts to 23 ft. lbs. (31 Nm) and the nuts to 74 ft. lbs. (100 Nm)
     
    Inlet and outlet radiator hoses
     
    Throttle body air inlet duct
     
    Air cleaner
     
    Hood and torque the bolts to 20 ft. lbs. (27 Nm)
     
    Fuel injector sight shield
     
    Negative battery cable
     

  12.  
  13. Fill the engine with new oil.
    NOTE
    A filter change is recommended.

  14.  
  15. Fill the cooling system.
  16.  
  17. Start the engine and check for leaks, repair if necessary.
  18.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Matchmark the hood hinges and remove the hood.
  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Fuel injector sight shield
     
    Torque converter cover
     
    Starter motor
     
    Engine flywheel-to-torque converter bolts
     
    Transaxle bracket
     
    Engine mount lower nuts
     
    Catalytic converter pipe from the right exhaust manifold
     
    Oil level harness retainer from the engine
     

  12.  
  13. Unplug and reposition the following electrical connections:

    Vehicle Speed Sensor (VSS)
     
    Oil pressure sensor
     
    Oil level sensor
     
    Knock sensors
     
    Heated Oxygen Sensor (HO 2 S)
     

  14.  
  15. Remove or disconnect the following:

    Oil filter adapter housing
     
    Engine ground nut and engine ground from the transaxle stud
     
    Bolt and the stud which attach the lower transaxle to the engine
     

  16.  
  17. Lower the vehicle while supporting the transaxle.

    Air cleaner assembly
     
    Fuel lines from the fuel rail
     
    Fuel vapor line
     
    Throttle and cruise control cables and bracket from the throttle body
     
    Water pump pulley bolts, loosen only
     
    Drive belt
     
    Water pump pulley bolts and the pulley
     
    Right and left engine mount struts
     
    Engine mount brackets from the radiator support
     
    Positive battery cable
     
    Engine cooling fans
     
    Vacuum booster hose from the engine
     
    A/C vacuum hose from the engine
     
    Power steering pump and lay aside with the lines attached
     

  18.  
  19. Unplug the upper engine electrical connectors from the following components:

    Fuel injectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) valve
     
    Evaporative Emissions (EVAP) purge solenoid
     
    Exhaust Gas Recirculation (EGR) valve
     
    Manifold Absolute Pressure (MAP) sensor
     
    Upper engine wiring harness from retaining clips and reposition the engine wiring harness for engine removal
     
    Radiator inlet and outlet hoses from the engine
     
    Heater hoses from the drive belt tensioner
     
    A/C compressor from the engine and set aside without disconnecting the lines
     

  20.  
  21. Install an engine lifting device.

    Bolts that attach the upper transaxle to the engine
     
    Engine from the vehicle
     

  22.  

To install:

  1. Installation is the reverse of removal, please note the following torques:

    Bolts attaching the upper transaxle to the engine to 55 ft. lbs. (75 Nm)
     
    A/C compressor-to-bracket nuts to 22 ft. lbs. (30 Nm)
     
    Power steering bolts to 25 ft. lbs. (34 Nm)
     
    Water pump pulley bolts to 116 inch lbs. (13 Nm)
     
    Bolt and the stud attaching the lower transaxle to the engine to 55 ft. lbs. (75 Nm)
     
    Engine ground nut to 26 ft. lbs. (35 Nm)
     
    Engine mount lower nuts to 58 ft. lbs. (78 Nm)
     

  2.  
  3. Fill the engine with new oil.
    NOTE
    A filter change is recommended.

  4.  
  5. Fill the cooling system.
  6.  
  7. Perform the Crankshaft Position (CKP) system variation learn procedure.
  8.  
  9. Start the engine and check for leaks, repair if necessary.
  10.  

4.3L Engine
  1. Remove or disconnect the following:

    Battery negative cable
     
    Coolant
     
    A/C refrigerant, if equipped
     
    Oil pan skid plate
     
    Engine shield

    Click image to see an enlarged view

    Fig. Engine shield removal

     



    Starter.
     
    Transmission cover
     
    Bolt holding the bracket for the starter cables and transmission cooler lines, if equipped
     
    Nuts at the catalytic converter pipe
     
    Exhaust pipes from the exhaust manifolds
     
    Bolts holding the brackets to the oil pan for both battery cables
     
    Crankshaft Position (CKP) sensor electrical connector and remove the harness from the retainer
     
    Low oil level sensor electrical connector and remove the wire harness from the retainer
     
    Bolt holding the battery negative cable and ground cable to the engine
     
    Torque converter-to-flywheel bolts, if equipped, through the starter opening
     
    Engine to transmission bolts

    Click image to see an enlarged view

    Fig. Hood in the service position

     

  2.  
  3. Move the hood hinge bolts to hold the hood in the service position.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.


    WARNING
    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.


    NOTE
    Remove the AIR pipes before engine removal. The AIR pipes can break or damage easily causing erratic engine operation.



    Positive Crankcase Ventilation (PCV) hose from the air cleaner outlet duct
     
    Air cleaner outlet duct from the throttle body and the air cleaner assembly
     
    Fan shroud
     
    Drive belt
     
    Engine cooling fan
     
    Radiator inlet and outlet hoses from the engine
     



    Accelerator control cable
     
    Cruise control cable from the throttle body and the bracket on the throttle body and intake manifold, if equipped
     
    Engine wiring harness and clip from the accelerator control cable bracket
     
    Accelerator control cable bracket from the throttle body
     
    A/C hoses from the compressor and the accumulator, if equipped
     
    Secondary Air Injection (AIR) crossover pipe from the AIR pipe assemblies
     



    AIR pipe assemblies from the left exhaust manifold, if equipped
     
    AIR pipe assembly from the AIR pump
     
    AIR pipe assembly from the right exhaust manifold, if equipped.
     
    A/C pressure switch, if equipped
     
    A/C compressor clutch, if equipped
     
    Exhaust Gas Recirculation (EGR) valve
     
    Battery positive cable
     
    Fuel meter body
     
    Idle Air Control (IAC) motor
     
    Throttle Position (TP) sensor
     
    Engine Coolant Temperature (ECT) sensor
     
    EVAP canister purge solenoid valve
     
    Manifold Absolute Pressure (MAP) sensor
     
    Ignition Control Module (ICM)
     
    Ignition coil
     
    Engine oil pressure gauge sensor
     
    Distributor
     
    Knock Sensor (KS)
     
    Nuts holding the bracket for the engine wiring harness to the intake manifold studs
     
    Bolt holding the engine wiring harness clip to the battery positive cable junction block bracket
     
    Bracket for the battery positive cable junction block from the power steering pump mounting bracket
     
    Battery positive and negative cables, if not done already
     
    Nut holding the ground wire to the stud at the rear of the right cylinder head
     
    Stud holding the engine wiring harness bracket to the rear of the right cylinder head
     
    Nut holding the engine wiring harness bracket to the stud for the EVAP canister purge solenoid valve
     
    Bolt holding the ground strap and the ground wire to the rear of the left cylinder head. Move the engine wiring harness aside.
     
    Both heater hoses from the engine and the cowl
     
    Distributor cap
     
    Fuel pipes at the rear of the engine
     
    Hose from the EVAP purge canister solenoid valve
     
    Power brake booster vacuum hose
     
    Nuts holding the power steering pump rear bracket to the side and front of the engine
     
    Three bolts and the nut holding the power steering pump mounting bracket to the engine
     

  6.  
  7. With the power steering pump and the A/C compressor still attached, slide the power steering pump mount bracket off the stud and set aside.

    Water outlet
     
    EGR valve inlet pipe from the intake and exhaust manifold
     

  8.  
  9. Attach the engine crane to the left front and right rear intake manifold mounting bolts.
  10.  
  11. Remove the engine motor mount to frame bracket bolts.
  12.  
  13. Support the transmission with a suitable jack.
  14.  
  15. Remove the engine.
  16.  

To install:

  1. Install or connect the following:

    Engine in the vehicle
     
    Engine mount to frame bracket bolts. Tighten the bolts to 50 ft. lbs. (65 Nm).
     

  2.  
  3. Remove the lifting device.
  4.  
  5. Apply thread lock GM P/N 12345382 or equivalent to the threads of the lower intake manifold bolts. Install the bolts and tighten as follows:
    1. First pass: 27 inch lbs. (3 Nm)
    2.  
    3. Second pass: 106 inch lbs. (12 Nm)
    4.  
    5. Final pass: 11 ft. lbs. (15 Nm)
    6.  

  6.  
  7. Loosely install one transmission to engine bolt. Remove the support jack from under the transmission.
  8.  
  9. Install the EGR valve inlet pipe to the intake and the exhaust manifold and tighten as follows:
    1. Tighten the EGR valve inlet pipe intake nut to 18 ft. lbs. (25 Nm).
    2.  
    3. Tighten the EGR valve inlet pipe exhaust nut to 22 ft. lbs. (30 Nm).
    4.  
    5. Tighten the EGR valve inlet pipe clamp bolt to 18 ft. lbs. (25 Nm).
    6.  

  10.  
  11. Install the water outlet.
  12.  
  13. Slide the power steering pump mounting bracket with the power steering pump and the A/C compressor on the stud.
  14.  
  15. Position the power steering pump rear bracket on the studs.
  16.  
  17. Install or connect the following:

    Power steering pump mounting bracket bolts and the nut
     
    Nut for the power steering pump rear bracket to the front of the engine. Tighten the power steering pump mounting bracket and the power steering pump rear bracket bolts and the nuts to 30 ft. lbs. (41 Nm).
     
    Fuel pipes
     
    Hose to the EVAP purge canister solenoid valve
     
    Vacuum brake booster hose to engine and the vacuum brake booster
     
    Distributor cap
     
    Both heater hoses to the engine and the cowl
     
    AIR pipe assembly with new gaskets to the right exhaust manifold, if equipped
     
    AIR pipe nuts and bracket bolt. Tighten the nuts to 18 ft. lbs. (25 Nm) and the bolt to 89 inch lbs. (10 Nm).
     
    AIR pipe assembly to the AIR pump
     
    AIR pipe assembly with new gaskets to the left exhaust manifold, if equipped. Install the AIR pipe nuts and bracket bolt. Tighten the to 18 ft. lbs. (25 Nm) and the bolt to 89 inch lbs. (10 Nm).
     
    AIR crossover pipe to the AIR pipe assemblies
     
    Engine wiring harness
     
    A/C pressure switch
     
    A/C compressor clutch
     
    EGR valve
     
    Alternator battery positive cable
     
    Fuel meter body assembly
     
    IAC motor
     
    TP sensor
     
    ECT sensor
     
    EVAP canister purge solenoid valve
     
    MAP sensor
     
    ICM
     
    Ignition coil
     
    Engine oil pressure gauge sensor
     
    Distributor
     
    KS
     

  18.  
  19. Install the bolt holding the ground strap and the ground wire to the rear of the left cylinder head. Tighten the ground strap and ground wire bolt to 12 ft. lbs. (16 Nm).
  20.  
  21. Position the engine wiring harness bracket on the EVAP purge canister solenoid valve stud and install the nut.
  22.  
  23. Install the stud holding the wire harness bracket to the rear of the right cylinder head. Tighten the nut on the EVAP solenoid to 80 inch lbs. (9 Nm). Tighten the stud at rear of the cylinder head to 18 ft. lbs. (25 Nm).
  24.  
  25. Install the nut holding the ground wire on the stud at the rear of the right cylinder head. Tighten the ground wire nut to 12 ft. lbs. (16 Nm).
  26.  
  27. Position the battery positive and negative cables. Do not connect the negative battery cable to the battery.
  28.  
  29. Install or connect the following:
    CAUTION
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.



    Battery positive cable junction block bracket and bolt to the power steering pump mounting bracket. Tighten the bolt to 18 ft. lbs. (25 Nm).
     
    Bolt holding the engine wiring harness bracket to battery positive cable junction block bracket
     
    Engine wiring harness bracket on the intake manifold studs. Tighten the nuts to 106 inch lbs. (12 Nm) and the bolt to 80 inch lbs. (9 Nm).
     
    A/C hoses
     
    Accelerator control cable bracket. Tighten the nuts to 80 inch lbs. (9 Nm).
     
    Engine wire harness and clip to the accelerator control cable bracket
     



    NEW accelerator control cable
     
    Cruise control cable
     
    Radiator inlet and outlet hoses
     
    Engine cooling fan
     
    Drive belt
     
    Upper and lower radiator shroud
     
    Air cleaner outlet duct to the throttle body and the air cleaner assembly
     
    PCV hose to the air inlet duct
     

  30.  
  31. Move the hood hinge bolts from the service position to the normal operating position.
  32.  
  33. Raise the vehicle.
  34.  
  35. Install or connect the following:

    Remaining transmission to engine bolts except for the one where the transmission cover mounts
     
    Torque converter to flywheel
     
    Transmission cover and bolts. Tighten the transmission cover to oil pan bolt to 106 inch lbs. (12 Nm). Tighten the transmission cover to transmission bolt to 34 ft. lbs. (47 Nm).
     
    Bolt holding the bracket for the starter cables and the transmission cooler pipe and tighten to 80 inch lbs. (9 Nm)
     
    Positive and negative battery cable brackets-to-oil pan bolts and tighten to 106 inch lbs. (12 Nm).
     
    Bolt for the battery negative cable and ground wire to the front of the engine. Tighten the battery negative cable and ground wire bolt to 18 ft. lbs. (25 Nm).
     
    CKP sensor and install the harness in the retainer
     
    Low oil level sensor and install the wire harness in the retainer
     
    Exhaust pipe to the exhaust manifolds and tighten the nuts at the catalytic converter flange
     
    Starter motor
     
    Oil pan skid plate and tighten bolt to 15 ft. lbs. (20 Nm)
     
    Engine shield
     

  36.  
  37. Lower the vehicle.

    Battery negative cable
     
    Engine oil
     
    Coolant
     

  38.  
  39. Recharge the A/C system.
  40.  

5.3L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine sight shield.
  6.  
  7. Evacuate the air conditioning (A/C) system and recover the refrigerant.
  8.  
  9. Remove the front tires and wheels.
  10.  
  11. Drain the cooling system.
  12.  
  13. Drain the engine oil.
  14.  
  15. Lower the vehicle.
  16.  
  17. Reposition the inlet hose clamp at the radiator.
  18.  
  19. Remove the inlet hose from the radiator.
  20.  
  21. Reposition the outlet hose clamp at the radiator.
  22.  
  23. Disengage the outlet hose clips from the fan shroud.
  24.  
  25. Remove the outlet hose from the radiator.
  26.  
  27. Remove the A/C compressor hose nut at the A/C receiver/dehydrator tube.
  28.  
  29. Remove the A/C compressor hose.
  30.  
  31. Remove the A/C compressor hose nut at the A/C condenser.
  32.  
  33. Remove the A/C compressor hose.
  34.  
  35. Remove the brake booster vacuum hose from the brake booster.
  36.  
  37. Remove the brake booster vacuum hose from the intake manifold.
  38.  
  39. Disconnect the engine harness electrical connectors from the instrument panel (I/P) harness electrical connectors.
  40.  
  41. Disconnect the brake fluid level switch electrical connector from the master cylinder.
  42.  
  43. Remove brake fluid from the master cylinder.
  44.  
  45. Disconnect the from brake pipe fittings from the master cylinder.
  46.  
  47. Disconnect the brake pipe fittings from the antilock brake (ABS) module.
  48.  
  49. Remove the master cylinder nuts.
  50.  
  51. Position the master cylinder to the engine. Hold the master cylinder in place using mechanic's wire.
  52.  
  53. Relieve the fuel system pressure.
  54.  
  55. Disconnect the fuel feed line from the fuel rail.
  56.  
  57. Disconnect the evaporative emission (EVAP) line from the purge solenoid.
  58.  
  59. Remove the right front fender diagonal brace.
  60.  
  61. Remove the underhood electrical center cover.
  62.  
  63. Loosen the 4 integral bolts attaching the fuse block. Reposition the fuse block.
  64.  
  65. Loosen the engine harness connector bolt. Remove the engine harness connector from the bracket.
  66.  
  67. Disconnect the camshaft position sensor lead.
  68.  
  69. Disconnect the engine harness electrical connector from the ABS module.
  70.  
  71. Disconnect the engine harness electrical connector from the electronic brake control module (EBCM).
  72.  
  73. Remove the air cleaner assembly.
  74.  
  75. Disconnect the following electrical connectors:

    Transmission control module (TCM)
     
    Engine control module (ECM)
     
    A/C pressure sensor
     

  76.  
  77. Disconnect the engine harness electrical connector from the crankshaft position (CKP) sensor harness.
  78.  
  79. Disconnect the engine harness electrical connector from the power steering gear harness.
  80.  
  81. Remove the clip attaching the power steering gear harness to the bracket.
  82.  
  83. Remove the shift cable clip.
  84.  
  85. Disconnect the shift cable from the transaxle selector lever stud.
  86.  
  87. Remove the shift cable from the bracket.
  88.  
  89. Remove the vehicle speed sensor (VSS) shield nut and bolt. Remove the shield.
  90.  
  91. Disconnect the engine harness electrical connector from the VSS.
  92.  
  93. Set all branches of the engine wiring harness on top of the engine.
  94.  
  95. Reposition the intermediate shaft lower boot.
  96.  
  97. Remove the intermediate shaft to steering gear bolt.
  98.  
  99. Separate the intermediate shaft from the steering gear.
  100.  
  101. Disconnect both front wheel speed sensors.
  102.  
  103. Unclip the ABS wire harness from the lower control arm.
  104.  
  105. Reposition the heater inlet and outlet hose clamps.
  106.  
  107. Remove the heater inlet and outlet hoses from the heater inlet/outlet pipe.
  108.  
  109. Raise and support the vehicle.
  110.  
  111. Disconnect the stabilizer links from the stabilizer shaft.
  112.  
  113. Disconnect the ball joints from the steering knuckles.
  114.  
  115. Disconnect the power steering pressure hose from the steering gear.
  116.  
  117. Disconnect the power steering pressure line clips from the frame.
  118.  
  119. Disconnect the outer tie rod ends from the steering knuckles.
  120.  
  121. Loosen the power steering hose clamp at the inlet pipe.
  122.  
  123. Remove the power steering hose from the inlet pipe.
  124.  
  125. Remove the left and right halfshafts from the transaxle.
  126.  
  127. Support the halfshafts using mechanic's wire.
  128.  
  129. Remove the transaxle oil cooler line bracket bolt/stud.
  130.  
  131. Disconnect the transaxle oil cooler lines from the transaxle.
  132.  
  133. Remove the positive battery cable nut from the starter.
  134.  
  135. Remove the cable terminal from the starter.
  136.  
  137. Remove the battery cable ground nut.
  138.  
  139. Remove the cable ground terminal from the stud.
  140.  
  141. Remove the battery cable retainers from the engine frame.
  142.  
  143. Disconnect the exhaust system.
  144.  
  145. Disconnect the O 2 sensor harness pigtail.
  146.  
  147. Remove the transaxle converter cover bolt/stud.
  148.  
  149. Remove the converter cover.
  150.  
  151. Remove the flywheel bolts.
  152.  
  153. Remove the front air deflectors.

    Click image to see an enlarged view

    Fig. Engine holding fixture J39580-5.3L engine

  154.  
  155. Raise the vehicle enough to place engine holding fixture J39580 under the engine, frame, and front suspension.
  156.  
  157. Support the rear of the vehicle with suitable jackstand.
  158.  
  159. Strap the front of the vehicle to the hoist.
  160.  
  161. Raise the engine holding fixture, or lower the vehicle to preload the weight of the engine, frame, and front suspension.
  162.  
  163. Remove the radiator to frame brackets.
  164.  
  165. Remove the engine frame front bolts.
  166.  
  167. Remove the engine frame rear bolts.
  168.  
  169. With the aid of an assistant, lower the engine holding fixture and/or raise the vehicle to remove the engine and the frame from the vehicle.
  170.  
  171. Ensure that all hoses, wires, and pipes clear the vehicle during the removal process.
  172.  
  173. Use a suitable engine lift to support the engine.
  174.  
  175. Remove the front engine mount to frame nuts.
  176.  
  177. Remove the rear engine mount to frame nuts.
  178.  
  179. Remove the transaxle to engine bolts and stud.
  180.  
  181. Separate the engine from the transaxle.
  182.  
  183. Using a suitable engine lift, remove the engine from the frame.
  184.  
  185. Install the engine onto a suitable engine stand.
  186.  

To install:

  1. Using a suitable engine lift, remove the engine from the engine stand.
  2.  
  3. Position and install the engine to the frame and the transaxle.
  4.  
  5. Install the transaxle to engine bolts and stud. Tighten the bolts/stud to 75 Nm (55 ft. lbs.).
  6.  
  7. Install the rear engine mount to frame nuts. Tighten the nuts to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the front engine mount to frame nuts. Tighten the nuts to 37 ft. lbs. (50 Nm).
  10.  
  11. Ensure that all hoses, wires, and pipes clear the vehicle during the installation process.
  12.  
  13. With the aid of an assistant, raise the engine holding fixture and/or lower the vehicle to install the engine and frame to the vehicle.
  14.  
  15. Install the engine frame rear bolts. Tighten the bolts to 160 Nm (118 ft. lbs.).
  16.  
  17. Install the engine frame front bolts. Tighten the bolts to 145 Nm (107 ft. lbs.).
  18.  
  19. Install radiator to front frame brackets.
  20.  
  21. Lower the engine holding fixture or raise the vehicle to preload the weight of the engine, frame, and front suspension.
  22.  
  23. Remove the support from under the rear of the vehicle.
  24.  
  25. Raise the vehicle enough to remove the engine holding fixture from under the engine, frame, and front suspension.
  26.  
  27. Connect the exhaust system and connect the O 2 sensor harness pigtail.
  28.  
  29. Install the flywheel bolts. Tighten the bolts to 63 Nm (47 ft. lbs.).
  30.  
  31. Install the converter cover.
  32.  
  33. Install the transaxle converter cover bolt/stud. Tighten the bolt/stud to 89 inch lbs. (10 Nm).
  34.  
  35. Install the left and right halfshafts into the transaxle.
  36.  
  37. Install the battery cable retainers to the engine frame.
  38.  
  39. Install the front air deflector.
  40.  
  41. Install the cable ground terminal to the stud.
  42.  
  43. Install the battery cable ground nut. Tighten the nut to 22 ft. lbs. (30 Nm).
  44.  
  45. Install the cable terminal to the starter.
  46.  
  47. Install the positive battery cable nut to the starter. Tighten the nut to 89 inch lbs. (10 Nm).
  48.  
  49. Connect the transaxle oil cooler lines to the transaxle.
  50.  
  51. Install the transaxle oil cooler line bracket bolt/stud. Tighten the bolt/stud to 18 ft. lbs. (25 Nm).
  52.  
  53. Install the power steering hose to the inlet pipe.
  54.  
  55. Tighten the power steering hose clamp at the inlet pipe. Tighten the clamp to 6 Nm (53 inch lbs.).
  56.  
  57. Connect the power steering pipe to the steering gear.
  58.  
  59. Connect the power steering pipe to the frame clips.
  60.  
  61. Lower the vehicle.
  62.  
  63. Position and install the ball joint nuts.
  64.  
  65. Install the sway links to the stabilizer shaft.
  66.  
  67. Install the tie rod ends to the steering knuckles.
  68.  
  69. Connect the wheel speed sensor electrical connectors.
  70.  
  71. Connect the wheel speed sensor wiring harness to the lower control arm.
  72.  
  73. Install the heater inlet and outlet hoses to the heater inlet/outlet pipe.
  74.  
  75. Reposition the heater inlet and outlet hose clamps.
  76.  
  77. Install the intermediate shaft to the steering gear.
  78.  
  79. Install the intermediate shaft to steering gear bolt. Tighten the bolt to 48 Nm (35 ft. lbs.).
  80.  
  81. Position the intermediate shaft lower boot.
  82.  
  83. Route all branches of the engine wiring harness to their correct locations.
  84.  
  85. Connect the engine harness electrical connector to the VSS.
  86.  
  87. Install the VSS shield. Install the VSS shield nut and bolt. Tighten the bolt/nut to 18 ft. lbs. (25 Nm).
  88.  
  89. Install the shift cable to the bracket.
  90.  
  91. Connect the shift cable to the transaxle selector lever stud.
  92.  
  93. Install the shift cable clip.
  94.  
  95. Install the clip attaching the power steering gear harness to the bracket.
  96.  
  97. Connect the engine harness electrical connector to the CKP sensor harness.
  98.  
  99. Connect the engine harness electrical connector to the power steering gear harness.
  100.  
  101. Connect the camshaft position sensor lead to the sensor.
  102.  
  103. Connect the following electrical connectors:

    ECM
     
    TCM
     
    A/C pressure sensor
     

  104.  
  105. Install the air cleaner assembly.
  106.  
  107. Connect the engine harness electrical connector to the EBCM.
  108.  
  109. Connect the engine harness electrical connector to the ABS module.
  110.  
  111. Install the engine harness connector to the bracket. Tighten the engine harness connector bolt. Tighten the bolt to 89 inch lbs. (10 Nm).
  112.  
  113. Position the fuse block. Tighten the 4 integral bolts attaching the fuse block. Tighten the bolts to 89 inch lbs. (10 Nm).
  114.  
  115. Install the electrical center cover.
  116.  
  117. Connect the fuel feed line to the fuel rail.
  118.  
  119. Connect the EVAP line to the purge solenoid.
  120.  
  121. Remove the mechanic's wire holding the master cylinder. Position the master cylinder to the brake booster.
  122.  
  123. Install the master cylinder nuts. Tighten the nuts to 33 Nm (24 ft. lbs.).
  124.  
  125. Connect the brake pipe fittings to the ABS module. Tighten the fittings to 15 Nm (11 ft. lbs.).
  126.  
  127. Connect the from brake pipe fittings to the master cylinder. Tighten the fittings to 22 ft. lbs. (30 Nm).
  128.  
  129. Connect the brake fluid level switch electrical connector to the master cylinder.
  130.  
  131. Connect the engine harness electrical connectors to the I/P harness electrical connectors.
  132.  
  133. Install the brake booster vacuum hose to the intake manifold.
  134.  
  135. Install the brake booster vacuum hose to the brake booster.
  136.  
  137. Install the A/C compressor hose.
  138.  
  139. Install the A/C compressor hose nut at the A/C condenser. Tighten the nut to 16 Nm (12 ft. lbs.).
  140.  
  141. Install the A/C compressor hose.
  142.  
  143. Install the A/C compressor hose nut at the A/C receiver/dehydrator tube. Tighten the nut to 16 Nm (12 ft. lbs.).
  144.  
  145. Install the outlet hose to the radiator.
  146.  
  147. Connect the outlet hose clips to the fan shroud.
  148.  
  149. Reposition the outlet hose clamp at the radiator.
  150.  
  151. Install the inlet hose to the radiator.
  152.  
  153. Reposition the inlet hose clamp at the radiator.
  154.  
  155. Install the front tires and wheels.
  156.  
  157. Connect the negative battery cable.
  158.  
  159. Install the right fender diagonal brace.
  160.  
  161. Refill the engine with oil.
  162.  
  163. Recharge the A/C system.
  164.  
  165. Refill the cooling system.
  166.  
  167. Bleed the brake system.
  168.  
  169. Check the transaxle fluid level, add fluid if necessary.
  170.  
  171. Install the engine sight shield.
  172.  
  173. Run the engine and inspect for leaks.
  174.  

 
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